Waterous CZ Series User manual

CZ Series Centrifugal
Fire Pumps
Operation and Maintenance
Form No.
F−1031
Section
2111
Issue Date
04/90
Rev. Date
6/4/20
Table of Contents
Safety Information ........................ 1, 2
General Description................................................3
Components..............................................................3
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Instructions............................................4
Pumping from Water Tank................................................4
Pumping from Hydrant or in Relay............................5
Pumping from Draft...................................................6
Fire Hose Testing......................................................7
Maintenance ............................................................8
Corrosion Protection..................................................8
Optional Intake Screens......................................8
Optional Anodes . . . . . . . . . . . . . . . . . . . . . 8
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mechanical Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figures:
Illustrations Overheat Protection Manager (OPM) . . . . . . . . . . . 9
1. CZ Series Fire Pump
2. CZU Series Fire Pump
. . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . . . . . . . . . . . . . . . 3
3. Zinc Intake Screens...................................................8
4. Bolt−on Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Threaded Anodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. CZ Pump....................................................................9
7. CZ and CZU Pump................................................. 10
Read through the safety information and
operating instructions carefully before
using your Waterous Fire Pump.
Visit us at www.waterousco.com
Waterous Company 125 Hardman Avenue South, South St. Paul, Minnesota 55075 USA (651) 450−5000
Instructions subject to change without notice.

F−1031, Section 2111
Page 1 of 10
! WARNING
Pressure Hazard. May result in personal injury.
Prior to connection or removal of hoses, caps or other
closures with pump intake or pump discharge connec-
tions, relieve pressure by opening drains or bleeder
valves. Bleeder valves should also be used while filling
a hose connected to an intake with water.
! WARNING
Death or serious personal injury might occur if proper
operating procedures are not followed. The pump op-
erator, as well as individuals connecting supply or dis-
charge hoses to the apparatus must be familiar with
these pump operating instructions as well as other
operating instructions and manuals for the apparatus,
water hydraulics and component limitation.
Safety Information
Read through the safety information and operating instructions carefully before using
your Waterous Fire Pump.
! WARNING
Scalding Water Hazard. May result in serious burns.
When operating the pump, be sure to open at least
one discharge valve slightly to prevent the pump from
overheating. If the pump runs for a few minutes com-
pletely closed, it may heat the water enough to scald
someone when the valve is opened. Overheating can
damage the packing, seals and other pump parts. If
the apparatus builder has installed a by−pass system
or other provision designed to prevent overheating,
opening a discharge valve may be unnecessary.

F−1031, Section 2111
Page 2 of 10
Safety Information
Read through the safety information and operating instructions carefully before using
your Waterous Fire Pump.
WARNING
Hose Testing Hazard. May result in serious personal injury.
Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken to
prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should not be
used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.
WARNING
Pressure Hazard. May result in serious personal injury.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST
be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed
between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event a
hose bursts during testing.
WARNING
Scalding Water Hazard. May result in serious burns.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be
circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must be
used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be
heated enough to scald someone when a valve is opened.

F−1031, Section 2111
Page 3 of 10
Introduction
This instruction contains the information needed for operation and maintenance of CZ Series centrifugal pumps.
General Description
The CZ Series centrifugal fire pumps are direct−drive, single stage, vertically−split and designed to operate from a water tank,
hydrant or from draft. CZ Series pumps are equipped with a 5” intake and are capable of pumping 950 gpm at 260 psi (3600
l/m @ 18 bar). CZU Series pumps are equipped with a 6” intake and are capable of pumping 1500 gpm at 250 psi (5675 l/m
@ 17.3 bar).
OPERATION LIMITS: Do not operate pump beyond max. pressure (350 psi) or max. speed (4000 rpm for CZ; 4200
rpm for CZU).
Fail to do that may result in personal injury or premature pump failure.
Body Assembly Components
tates with the impeller shaft. It presses against a highly
polished (lapped), silicone carbide, stationary ring that is
This assembly includes the body, intake and discharge
adapters, bearing housing and related parts. The body
and adapters are either cast iron or bronze.
Impeller Shaft Assembly
This assembly consists of a bronze impeller mounted on a
stainless steel shaft with wear rings, mechanical seal and
related parts. The impellers are balanced and the impeller
shaft is supported by ball bearings.
Mechanical Seals
CZ
The mechanical seal consists of a flat, highly polished
(lapped), spring−fed carbon ring that is sealed to and ro-
sealed in the pump body. This seals the shaft and pre-
vents air from entering and water from leaving. A mechan-
ical seal does not leak or drip water, even when pumping.
CZU
The mechanical seal consists of a flat, highly polished
(lapped), spring−fed carbon ring that is seated in the pump
volute. It presses against a highly polished (lapped),
stainless steel ring that is seated in and rotates with the
impeller. This seals the shaft and prevents air from enter-
ing and water from leaving. Additional O−rings around the
washer help keep the shaft dry during pump operation. A
mechanical seal does not leak or drip water, even when
pumping.
Intake Screens Options
Anodes
Zinc die cast screens are normally used in the intake fit-
tings, with brass screens available optionally. Although the
screens are chemically treated (coated) to inhibit corro-
sion, the water being pumped may still corrode the
screens. Such corrosion is ‘‘sacrificial’’; that is, it will help
prevent corrosion in the rest of the pump the same way
the magnesium anodes protect the metal parts of a water
heater.
As additional corrosion protection for iron body pumps,
Waterous has anodes available to fit any unused opening
in the intake fitting. Anodes provide an additional sacrificial
surface to the water to supplement the intake screens.
Overheat Protection Manager (OPM)
The Overheat Protection Manager (OPM) acts as a safety
device by releasing hot water to the ground or back to the
water tank from the discharge area of the pump.
Figure 1. CZ Series Fire Pumps Figure 2. CZU Series Fire Pumps
IL 1624 IL 1625

F−1031, Section 2111
Page 4 of 10
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections,
relieve pressure by opening drains.
! WARNING
Scalding Water Hazard. May result in serious
burns.
When operating the pump, be sure to open at least
one discharge valve slightly to prevent the pump from
overheating. If the pump runs for a few minutes com-
pletely closed, it may heat the water enough to scald
someone when the valve is opened. Overheating can
damage the packing, seals and other pump parts. If
the apparatus builder has installed a by−pass system
or other provision designed to prevent overheating,
opening a discharge valve may be unnecessary.
CAUTION
Freezing water hazard. May cause damage to
the pump.
If the pump is exposed to freezing temperatures,
drain all water from pump, lines and accessories.
CAUTION
Do not attempt to pump more water than is
available from water tank. Always make sure
compound gage reading stays above zero.
OperatingInstructions
Pumping from Water Tank
After Pumping
1. Disengage pump drive.
2. If pumping anything but clean water, remove all
intake and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh wa-
ter for several minutes to remove all traces of impuri-
ties.
3. If pump is kept full of water when not in use, make
sure water is clean and non−corrosive. Make sure
the pump is completely full or completely drained −
never partially full.
1. Open valves in piping between water tank and pump
intake, and at least one discharge valve.
2. Allow about 30 seconds for water to flow into pump.
NOTE: Priming the pump may be necessary under
some conditions because of air trapped in pump and
piping.
3. Engage pump drive and accelerate engine to obtain
desired discharge pressure and capacity.
4. Close all drains and install intake and discharge caps.
5. If truck is equipped with a priming pump, operate it un-
til fluid is discharged from priming pump discharge pi-
pe. Also check fluid level in priming tank, and refill if
necessary.
For pump and roll operation, engage the PTO as di-
rected by the apparatus builder.
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
NOTICE

F−1031, Section 2111
Page 5 of 10
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections,
relieve pressure by opening drains or bleeder valves.
! WARNING
Scalding Water Hazard. May result in serious
burns.
When operating the pump, be sure to open at least
one discharge valve slightly to prevent the pump from
overheating. If the pump runs even for a few minutes
completely closed it may heat the water enough to
scald someone when the valve is opened. Overheat-
ing can damage the packing, seals and other pump
parts.If the apparatus builder has installed a by−pass
system or other provision designed to prevent over-
heating, opening a discharge valve may be unneces-
sary.
Pumping from Hydrant or in Relay
After Pumping
NOTE: Limit inlet pressure to 150 psi (10.3 bar) if
possible. The pump will operate properly with higher
intake pressure but it will accelerate mechanical seal
wear.
1. Engage pump drive.
2. Open intake, hydrant and other valves as necessary
to allow water to enter pump.
NOTE: Bleeder valves should be used while fill-
ing a hose connected to an intake with water.
3. Open discharge valves and accelerate engine to ob-
tain desired discharge pressure and capacity.
4. Set relief valve or other pressure governing device to
desired pressure.
1. Disengage pump drive.
2. If pumping anything but clean water, remove all
intake and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh wa-
ter for several minutes to remove all traces of impuri-
ties.
3. If pump is kept full of water when not in use, make
sure water is clean and non−corrosive. Make sure
the pump is completely full or completely drained −
never partially full.
4. Close all drains and install intake and discharge
caps.
5. If truck is equipped with a priming pump, operate it
until fluid is discharged from priming pump discharge
pipe. Also check fluid level in priming tank, and refill
if necessary.
CAUTION
Freezing water hazard. May cause damage to
the pump.
If the pump is exposed to freezing temperatures,
drain all water from pump, lines and accessories.
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains or bleeder valves.
CAUTION
Do not attempt to pump more water than is
available from hydrant or relaying pumper. Al-
ways make sure compound gage reading stays
above zero.
NOTICE
NOTICE

F−1031, Section 2111
Page 6 of 10
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to connection of hoses, caps or other closures
with pump intake or pump discharge connections,
relieve pressure by opening drains.
! WARNING
Scalding Water Hazard. May result in serious
burns.
When operating the pump, be sure to open at least
one discharge valve slightly to prevent the pump from
overheating. If the pump runs even for a few minutes
completely closed it may heat the water enough to
scald someone when the valve is opened. Overheat-
ing can damage the packing, seals and other pump
parts. If the apparatus builder has installed a by−pass
system or other provision designed to prevent over-
heating, opening a discharge valve may be unneces-
sary.
CAUTION
Freezing water hazard.
May cause damage to the pump.
If the pump is exposed to freezing temperatures,
drain all water from pump, lines and accessories.
Pumping from Draft
After Pumping
1. Disengage pump drive.
2. If pumping anything but clean water, remove all
intake and discharge caps, open all valves and open
all drains. Flush entire system with clean, fresh wa-
ter for several minutes to remove all traces of impuri-
ties.
3. If pump is kept full of water when not in use, make
sure water is clean and non−corrosive. Make sure
the pump is completely full or completely drained −
never partially full.
NOTE: To get full capacity, quick prime and maintain
pump efficiency:
a.) Position truck as near as possible to water supply.
b.) Avoid humps or sharp bends in intake hose. Make
sure no part of hose is higher than pump intake inlet.
(Air pockets in intake hose may cause loss of prime
or erratic pump action and may reduce pump capac-
ity.)
c.) Make sure all intake connections are tight and dis-
charge valves are closed.
d.) Immerse intake strainer at least two feet below water
surface to prevent pump from drawing air (Whirl-
pools forming above intake strainer indicate that
strainer is too close to surface of water.)
e.) Make sure intake strainer is far enough from bottom
to prevent pumping sand, gravel or other foreign
matter.
1. Prime the pump. (See separate instructions supplied
with primer.)
2. Engage pump drive.
3. Open discharge valves and accelerate engine to ob-
tain desired discharge pressure and capacity.
4. Set relief valve or other pressure governing device to
desired pressure.
4. Close all drains and install intake and discharge
caps.
5. If truck is equipped with a priming pump, operate it
until fluid is discharged from priming pump discharge
pipe. Also check fluid level in priming tank, and refill
if necessary.
! WARNING
Pressure Hazard. May result in personal injury or
death.
Prior to removal of hoses, caps or other closures with
pump intake or pump discharge connections, relieve
pressure by opening drains.
NOTICE

F−1031, Section 2111
Page 7 of 10
Fire Hose Testing
WARNING
Hose Testing Hazard. May result in serious personal injury.
Due to a potential for catastrophic hose failure during service testing of fire hose, it is vital that safety precautions be taken to
prevent exposure of anyone to this danger. Fire pumps on fire department apparatus are not designed for and should not be
used for service testing of fire hoses. Hose testing machines should be used for service testing of fire hoses.
NFPA 1962 Standard for the Inspection, Care, and use of Fire Hose, Couplings, and Nozzles and the Service Testing of Fire
Hose provides requirements and testing procedures for service-testing fire hose at least annually. NFPA 1962 includes
procedures for service testing with either a hose testing machine or with a pump on a fire department fire apparatus.
WARNING
Pressure Hazard. May result in serious personal injury.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, the procedures in NFPA 1962 MUST
be followed including the use of a fire department gate valve with a ¼-inch (6 mm) hole drilled through the gate installed
between the fire apparatus discharge outlet and the hose test layout to prevent a volume surge from the pump in the event a
hose bursts during testing.
During fire hose testing with a fire pump on a fire department fire apparatus, the fire pump is required to be operated at high
discharge pressure with little or no flow out of the apparatus.
WARNING
Scalding Water Hazard. May result in serious burns.
If a fire pump on a fire department apparatus is used for service testing of fire hoses, pump discharge water must be
circulated through a by-pass system or discharged through a slightly open discharge valve, or some other provision must be
used to prevent overheating. If the pump runs for a few minutes without adequate flow through the pump, water may be
heated enough to scald someone when a valve is opened.
CAUTION
If a fire pump on a fire department apparatus is used for service testing of fire hoses, operating the pump at high discharge
pressure with little or no flow may result in severe damage to the pump.
NOTICE

F−1031, Section 2111
Page 8 of 10
Maintenance
Optional Intake Screens CorrosionProtection
Figure 4. Bolt−on Anodes
Once per month check to make sure the intake screens
are not clogged or damaged. Also check for corrosion, and
replace screens if damage is severe. For the screen to
adequately control corrosion, there must be a strong
electrical contact between the screen and the fitting.
Remove any corrosion, debris or paint from the counter
bore that will insulate the screen from the intake fitting. If
the screen does not fit tightly, adjust the gap of the slot on
the outside diameter of the screen to ensure a tight fit.
NOTE: These screens are die−cast which results in a
slight taper from one side to the other. Install the
screen with the thinner cross−section facing out to
minimize flow restriction.
Figure 3. Intake Screens
Optional Anodes
Twice per year, remove the anodes and check for erosion
of the replaceable elements. Replace the elements if more
than half of either of the elements has eroded.
Anodes are normally mounted on the pump intake piping,
but they may also be installed in the discharge piping if no
intake mounting locations were available. Physical mount-
ing of the anode may be via an NPT tap or bolt−on flange
as described below.
NOTE: The replaceable elements must make contact
with water to be effective. Do not paint or use any
other coating on the replacement elements.
Bolt−on Anodes
Unscrew the (4) hex head screws from the pump. If
elements require replacement, unscrew the hex head
cap screw.
NOTE: There is no need to remove the threaded
anode adapter from the anode flange for element
replacement. The screw was installed using thread
sealant so higher force than normal may be
necessary to remove.
Replace one or both elements as necessary. Install the hex
head screw using Loctite 242 (blue) on the screw threads.
Mount the anode assembly back on the fitting.
Threaded Anodes
NOTE: The 2−1/2 in. hex is threaded into a bushing
that should remain on the pump. Be sure to restrain
the bushing when removing the 2−1/2 in. hex.
Unscrew the 2−1/2 in. hex from the pump. If the elements
require replacement, unscrew the hex head cap screw.
NOTE: The screw was installed using thread sealant
so higher force than normal may be necessary to
remove.
Replace one or both elements as necessary. Install the
hex head screw using Loctite 242 (blue) on the screw
threads. Remove any paint or corrosion from the face
around the NPT tap on the pump. Apply thread sealant to
the threads and screw the 2−1/2 in. hex into the pipe tap
until tight.
Figure 5. Threaded Anodes

F−1031, Section 2111
Page 9 of 10
CAUTION
Prolonged dry pump operation or operating a dry
pump at high speeds will reduce the life of the
mechanical seal.
Lubrication
A fluid splash system, within the bearing housing, lubri-
cates the bearings. Check fluid level monthly by remov-
ing the square head pipe plug on side of bearing housing
marked OIL LEVEL. The oil should be level with the bot-
tom of the hole.
Toadd fluid, remove filler plug or breather on the bearing
housing and pour fluid through the opening. Fill to bot-
tom thread of oil level hole. Do not Overfill.
Use non−detergent SAE 30 oil.
Drain bearing housing by removing magnetic drain plug
from bottom and refill with new lubricant after each accu-
mulated 100 hours of pump operation, or at least every
spring and fall. (Under severe service conditions, where
pump has been used continuously at high output,
change fluid more frequently.) The capacity is approxi-
mately 1/4 quart. Be sure to clean drain plug and breath-
er.
Figure 6. CZ Pump
Mechanical Seal
A mechanical shaft seal is used and no adjustment is
required. When the pump operates, the water being
pumped cools and lubricates the shaft seal to prevent it
from overheating.
If the mechanical seal leaks, replace the entire seal.
The same drain (weep hole) is used to vent the mechan-
ical seal on the pump shaft and the oil seal for the bear-
ing housing. Inspect for water (mechanical seal) or oil
(oil seal) leaks.
Overheat Protection Manager
Check the electrical circuit by pressing the test button
located on the panel plate every 100 hours of pump op-
eration or every six months, whichever comes first.
If the light does not flash, the light bulb or flasher may
need replacement (provided all wire connections are
solid).
CAUTION
Fluid temperature hazard.
May cause premature seal wear and d
0
amage.
Fluid temperature should not exceed 250 F
(121 C) for an extended period of time in order to
prevent seal wear and damage.
CAUTION
If fluid level is low, locate the source of the leak
and repair. If the fluid level is high, loosen the
drain plug until the fluid drops to the proper level.
If excessive water drains out, change the fluid
and determine the source of the water leakage
and repair.
NOTICE
NOTICE
NOTICE

F-1031, Section 2111
Page 10 of 10
Figure 7. Cross-Sectional View, CZ and CZU